JPH1179407A - Random palletizing device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a random palletizing device whereby stowage along order of distributing feed route can be performed. SOLUTION: In a personal computer connected through a host physical distribution computer and Ether-Net or the like, a plurality of stowage devices are connected. In a screen of the personal computer, an input display screen 40, total unit style of packing vertical figure screen 42, and a total unit style of packing plan screen 44 are displayed. An operator, by indicating a position desired to stow a load of box or the like on the total unit style of packing vertical figure screen 42 and the total unit style of packing plan screen 44 by a mouse, can easily assign a position with stowage desired.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a random palletizing apparatus for loading a plurality of loads on a pallet.

[0002]

2. Description of the Related Art Conventionally, in the logistics industry, transshipment of goods is performed everywhere, but it is difficult to mechanize it, and the transshipment of goods has been digested as a repetition of simple work by hand. In recent years, with the advancement of robot technology, the wave of mechanization has come to the world of logistics.

[0003] However, it has been extremely difficult to realize a mixed stacking operation (random palletizing) of different types according to various orders. The inventor of the present application has proposed Japanese Patent Application Nos. 3-274263 and 4-186735 as methods for realizing such random palletizing.

[0004] Japanese Patent Application No. 3-274263 proposes performing random palletizing (flat stacking) by a combination of an automatic warehouse and a robot. In Japanese Patent Application No. 4-186735, random palletizing (flat stacking) is realized by combining an automatic warehouse or conveyor, a stacking teaching device, and a balancer.

[0005]

However, in each of the random palletizing methods described above, since the stacking is basically flat, it is not possible to carry out the preloading, that is, stacking (sticking) along the order of the delivery route. There's a problem.

The present invention has been made in view of the above problems, and an object of the present invention is to provide a random palletizing apparatus capable of stacking bars.

[0007]

According to a first aspect of the present invention, a plurality of cargoes are conveyed to solve the above problems.
In a random palletizing device loaded on a pallet using a manipulator based on an instruction of an operator, the appearance of a plurality of conveyed loads is displayed to show to the operator, and the operator is provided with the plurality of loads. Input display means for informing the size and shape, information display means for displaying the contents of the plurality of conveyed loads to the operator, and stacking indicating the state in which the loads are being loaded on the pallet Output display means for displaying a figure to show to the operator; and a position on the stacking figure displayed by the output display means, on the basis of an instruction of the operator, indicating a position at which a load is to be next loaded. Instructing means, an optimal loading position calculating means for finding an optimal loading position based on the position instructed by the instructing means, and an optimal loading position calculating means The optimum loading position comprises a sending means for sending to the manipulator, the contents of the cargo,
A random palletizing apparatus including at least a type and an article name of the load and loading the load on the manipulator at an optimum loading position.

According to a second aspect of the present invention, in the random palletizing apparatus according to the first aspect of the present invention, the random palletizing apparatus further comprises an operation guidance display means for providing the operator with an operation guidance for instructing a method of performing a stacking operation. And a random palletizing device.

[0009] A third aspect of the present invention provides a random palletizing apparatus according to the first aspect of the present invention.
The output display means displays a perspective view display means for displaying a perspective view of a load loaded on the pallet as viewed obliquely, and a plan view showing a load state of the load loaded on the pallet viewed from above. And a plan view display means.

[0010] A fourth aspect of the present invention provides a random palletizing apparatus according to the first aspect of the present invention.
2. The random palletizing apparatus according to claim 1, wherein said instruction means includes temporary placement instruction means for instructing to load the cargo not on said pallet but in a temporary storage place.

According to a fifth aspect of the present invention, there is provided a random palletizing apparatus according to the first aspect, wherein
The real-time mode further includes control means for switching an operation mode between a real-time mode and a simulation execution mode. In the real-time mode, the robot actually loads a load on a pallet according to an instruction of the operator, and executes the simulation. In the mode, virtual loading is performed on a computer without actual loading of the cargo, a simulation stage for storing the loading procedure, and a loading of the loading stored in the simulation stage after the execution of the simulation stage. An execution stage for loading an actual load based on a procedure is executed, and a random palletizing apparatus is characterized in that two stages are executed.

In the first embodiment of the present invention, the next loading position can be indicated by using the indicating means on the diagram showing the state of loading of the cargo displayed by the output display means.
Efficient loading is possible. Further, since the type and name of the operated cargo are displayed, the operator can know the contents of the cargo accurately.

[0013] Since the operation guidance display means in the second aspect of the present invention displays an operation method, even an operator unfamiliar with the palletizing apparatus can perform an operation based on the displayed operation method.

The output display means in the third aspect of the present invention displays a perspective view and a plan view, so that the instruction means can accurately indicate the position where the cargo is to be loaded.

According to the temporary storage instruction means in the fourth aspect of the present invention, it is possible to instruct to place the conveyed load at the temporary storage place.

The control means of the present invention controls to switch between a real-time mode and a simulation execution mode. Therefore, it is possible to virtually load the cargo before actually loading the cargo.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 shows a system configuration diagram of a random palletizing apparatus according to a preferred embodiment of the present invention. As shown in FIG. 1, an upper physical distribution computer 10 for controlling physical distribution and a personal computer (hereinafter referred to as a personal computer) 12 for controlling a random palletizing device are connected by RS232C, Ether-Net, or the like. . Note that the personal computer 12 is also suitable to use EWS or the like.

The random palletizing apparatus according to the present embodiment comprises this personal computer 12 and a plurality of loading devices. As shown in FIG. 1, the loading device includes a normal loading device 14 directly controlled by the personal computer 12 and a sequencer communication station 16.
And a network loading device 18 forming one terminal of the network.

The normal loading device 14 includes a robot control device 20, a robot 22, and a sequencer 24. The sequencer 24 controls, for example, a positioning conveyor or the like, and controls a position where the positioning conveyor stops.

The network loading device 18 includes the sequencer communication station 16 described above and the robot control device 26
, A robot 28, and a sequencer 30.

In the present embodiment, the host computer 10 and the personal computer 12 have different configurations. However, the personal computer 12 may be configured to also serve as the host computer 10.

FIG. 2 shows a screen of the personal computer 12 of the random palletizing apparatus according to the present embodiment. As shown in FIG. 2, an input display screen 40 is shown on the left side of the screen. With this input display screen 40, the operator can grasp the size and shape of the cargo that is carried to the conveyor. At the bottom of the input display screen 40, an overall package elevation view screen 42 is shown. The overall package elevation view is a view when the load is stacked on the pallet when viewed obliquely, and can realistically represent the load being loaded. In the overall cargo elevation view, the space where the cargo is to be loaded on the pallet is shown as a solid, and the black portion represents the pallet.

On the right side of the whole package elevation view screen 42, a whole package plan view screen 44 is shown. The plan view of the entire package is a view of the state of the cargo being stacked on the pallet as viewed from directly above. An operation guidance screen 46 for instructing an operation to be performed next is shown on the right side of the overall package appearance plan view screen 44. From this operation guidance screen,
The operator can instruct a desired operation with a mouse.

On the upper right of the screen of the personal computer 12, there is provided an information display screen showing information such as the contents of the cargos so far loaded. As shown in FIG. 2, various information such as the number of cardboard boxes, the number of plastic boxes, and the contents of slips are displayed in addition to the type and name of the cargo to be stowed. I have.

The operation guidance screen 46 has a predetermined hierarchical structure in order to make it easy to instruct an operation. As shown in FIG. 3, first, in the first hierarchy 50,
Four menus, “from conveyor to pallet”, “from conveyor to temporary storage”, “from temporary storage to pallet”, and “river change” are shown. The operator selects a desired operation from these four menus, and clicks the left mouse button on the selected menu.

When "from conveyor to pallet" is selected on the first level 50, the second level 52a appears on the operation guidance screen 46. This is an operation selected when a cardboard box, a folding container, or the like conveyed by a conveyor is directly loaded on a pallet. As shown in FIG. 3, the second hierarchy 52a is provided with two menus, “do not rotate” and “rotate 90 °”. This specifies whether the cardboard boxes conveyed by the conveyor are to be stacked on the pallet in the same direction or to be changed by 90 ° and stacked.

Upon completion of this designation, a new third hierarchy 54a appears on the operation guidance screen 46. In the third level 54a, a message "Where on the pallet?" Is displayed, and the position on the whole package elevation view screen 42 is designated by the mouse. The designation is made by clicking the left mouse button. By the above operation, each load can be loaded on the pallet.

When "from conveyor to temporary storage" is selected on the first level 50, the second level 52b appears on the operation guidance screen 46. Here, the temporary placement refers to a place where the cargo such as cardboard is temporarily placed, and the cargo is temporarily placed in order to extend the operation of loading the pallet first.

According to the present embodiment, as described above,
Eight cargoes conveyed can be confirmed in advance on the input display screen 40. If you are a palletizing expert, just look at these eight cargoes,
It is possible to instantly judge where it is optimal to place the next cargo, but when an unfamiliar one operates, the judgment may be lost. Therefore, it is convenient to have a place where the cargo is temporarily put on the pallet without being put on the pallet. The “from conveyor to temporary storage” is a menu of operations selected in such a case.

When "from conveyor to temporary storage" is selected on the first level 50, a second level 52b is displayed.
The state of the second hierarchy 52b is shown in FIG. As shown in FIG. 3, the second layer 52b has a completely similar screen configuration to the second layer 52a. In this second level 52b, similarly to the second level 52a, when it is specified whether or not to rotate a cardboard or the like to be stacked, a third level 54b appears on the operation guidance screen 46 next. In the third hierarchy 54b,
Five menus of “temporary storage place 1”, “temporary storage place 2”, “temporary storage place 3”, “temporary storage place 4”, and “temporary storage place 5” are displayed, and the operator is transported from the conveyor. The user designates where the temporarily placed cargo is temporarily stored by selecting the menu. The menu is selected by moving the mouse cursor over the menu to be selected and pressing the left mouse button.

On the other hand, when the menu “from temporary storage to pallet” is selected on the first level 50, the second level 52 c appears on the operation guidance screen 46. This is a menu for an operation indicating that the cargo placed in the temporary storage place when the above-mentioned “from conveyor to temporary storage” menu is selected is placed on the pallet from the temporary storage place. Even when this menu is selected, similarly to the second layers 52a and 52b, the second layer 52c having two menus of "do not rotate" and "rotate 90 °"
Is displayed on the operation guidance screen 46. When one of the menus is selected on the second level 52c, a third level 54 for specifying a temporary storage location from which the cargo is to be transferred is designated.
The screen shifts to screen c. In the third hierarchy 54c,
Similarly to the above-described second level 54b, by clicking the left mouse button, a place to pick up the loaded luggage is specified.

After the desired location is specified on the third level 54c, the fourth level 56 prompting the user to specify the destination is displayed.
Is displayed on the operation guidance screen 46. The message “Where on the pallet” is written in the fourth hierarchy 56, and the operator follows the message according to the message.
By pointing the mouse cursor on the whole package elevation view screen 42, the loading position can be designated.

The menu on the first level 50 includes:
As shown in FIG. 3, there is a “river change”, which is to change the row of the bar stack.

All selections are made by clicking the left mouse button. In the present embodiment,
By clicking the right button, an erroneous selection can be canceled.

As described above, the random palletizing apparatus according to the present embodiment is configured so that the operator designates the stacking position with the mouse. here,
The designated loading position is transmitted to the robot, and the robot sequentially loads cardboard boxes, folding containers, and the like on the pallet as instructed.

Hereinafter, various features of each element technology of the random palletizing apparatus according to the present embodiment will be described.

A. Data Structure A-1 Realizing Box Correlation Recognition A-1 Basic Management of Box FIG. 4 is an explanatory diagram of the data structure of one box. As shown in FIG.
N ＄ (−) is a structure composed of 18 elements for one box. The loading target of the random palletizing device in the present embodiment is, as described above, a cardboard box,
Since it is a rectangular parallelepiped such as a folding container, in the following description, the objects to be loaded are generically referred to as "boxes".

As shown in FIG. 4A, JYO
The box position is recorded as relative coordinates on the pallet in UDAN @ (-). These relative coordinates are X and Y coordinates. The relative coordinates have the origin at the lower left of the pallet. Then, the values of the length, width and height of the box are recorded. An explanatory diagram of the relative coordinates is shown in FIG.

In FIG. 4 (a), "placed bottom height"
Represents the height of the bottom of the box. This height is the height from the upper surface of the pallet. Similarly, “placed upper surface height” indicates the height of the upper surface of the box. This height is also the height from the upper surface of the pallet. The “free area of the upper surface of the user” refers to the area of the upper surface of the box, on which no other box is placed. An explanatory diagram of this free area is shown in FIG.
It is shown in (c).

The “topmost forward link” in FIG. 4A is a pointer indicating a link for forming a list of boxes located at the top. This pointer is provided with two items, “topmost forward link” and “topmost back link”. As a result, a list of data of the uppermost box, which is a collection of only the data of the uppermost box, is formed. In the case of a box that is not positioned at the top, the two link columns are blank. That is, the box in which this link is described forms a set (list) of boxes located at the top.

Referring to FIG. 4A, "intercept b1 when three-dimensionally mapped to two-dimensionally" will be described. The “intercept b1 when three-dimensionally mapped to two-dimensionally” is shown in FIG.
As shown in (2), when this box is mapped two-dimensionally, the side of the box in the Z-axis direction is the Y-intercept that intersects with the Y-axis, and is the Y-intercept having the largest value. In addition, there are four sides,
Although there are four Y-intercepts, the one with the largest value is called this b1, and these are called b2, b3, and b4 in order of magnitude.
However, as shown in FIG. 4A, only “b2” and “b4” other than “b1” are stored in the data structure.

As other coordinate information, FIG.
As shown in (a), the Y coordinate of the vertex p7 and the Y coordinate of the vertex P1 are recorded.

As described above, the data structure of a box is described as forming a list structure by pointers linking the data of each box. However, the data structure also includes a pointer indicating a drawing order. I have. This pointer is
In (a), “drawing order forward link”
Two types of pointers, “drawing order back link”, are provided. This drawing order represents the drawing order of each box in the above-described overall package elevation view.

What is characteristic in the present embodiment is that the drawing order of each box is defined by the list structure in the drawing of the above-described overall package elevation view. Generally, hidden line processing is a major problem in drawing a three-dimensional object. In the present embodiment, the drawing is performed from the box at the back, so to speak, based on the positional relation and the overlapping relation of the boxes when drawing. That is,
A box that is hidden by another box is drawn before the box to be hidden, and is overwritten when the box to be hidden is drawn, thereby automatically expressing the state of being hidden. As described above, drawing from the farther object has been performed conventionally, but in the present embodiment, corresponding to the packing of boxes, the data structure of the box The drawing order is calculated by operating the pointer indicating the drawing order. The operation of the drawing order pointer, which is one of the features of the present embodiment, will be described later in detail.

As shown at the end of FIG.
At the end of the data of each box, a code indicating the type of the box is recorded. The position on the right side of FIG. 4A shows the position of each item in the data and the length.

A-2 . Existence of Possibility of Other Boxes on Top of FIG. 5 FIG. 5 shows “topmost forward link” and “topmost back” in the data structure shown in FIG.
An explanatory diagram showing that only the uppermost box has a list structure using "link". In the present embodiment, this data structure is called the uppermost list structure. This top-level list structure is a list structure in which the height of the top surface of the box is high. In the case of a box on which another box is placed, the list is limited to those having a free area of 350 cm ² or more. It is included inside.

As shown in FIG. 5, UELIST
The box whose address is specified by the uppermost link list FIRST (-) is the box whose top surface is higher than all the boxes. The “topmost forward link” of the box having the highest height at the top indicates the address of the data of the box having the next highest height.

For example, in the example shown in FIG. 5, box 2 is the highest box at the top, and box 4 is next highest. The box 9 is the lowest box. That is, the boxes 1 and 3 are not included in the uppermost list structure. Note that a pallet is included in the data structure as the "box" at the bottom in JYOUDAN @ (-). If no boxes are stacked on the pallet, the pallet is recorded as a "box" having the same top surface area as its plane area in this data structure JYOUDAN @ (-). . As described above, the data in each box is linked not only with the “top-level forward link” but also with the “top-level back link”, and data can be accessed in ascending order of the top-level. It is possible.

In the present embodiment, the "top link" in the data of the box having the highest top surface
And the "top f" in the data of the box having the lowest top
In the “old link”, “φ” is stored.
Based on this “φ”, the highest box or the lowest box is detected.

In the present embodiment, since the boxes located on the uppermost surface are managed in a list structure, there is an effect that arithmetic operations such as a box search operation become faster.

A-3 Things that are hidden behind human eyes (Robo
Management of the possibility of hand-to-hand interference) The decision that a part (or all) of a box that is about to be stacked appears to be partially (or entirely) hidden to humans because of the presence of a box with a top surface higher than its bottom surface in the foreground This is very important in terms of man-machine interface (or robot hand interference).

As described later, the hiding judgment is made. When it is judged that the object is hidden, it is necessary to draw the object first in the graphic display. This hiding decision always requires a recursive decision. The reason for this is that a new box may be inserted between two boxes that are far apart and have no relationship in drawing, which may cause a relationship.

A-4 Hidden Judgment A method of hiding judgment in the present embodiment will be described with reference to FIG. FIG. 6 shows two boxes whose two hidden relationships are to be tested. And these 2
The figure shows a case in which two boxes are mapped and displayed two-dimensionally. In FIG. 6, it is drawn by a thin line, and the vertex p
The boxes having b1 to pb7 are boxes B to be subjected to a hidden inspection, and an adjacent box A inspects whether or not the box is hidden. As shown in FIG. 6, the box A is drawn with a thick line, and the vertices pa1 to pa7
It is a box having.

When the boxes A and B are mapped two-dimensionally, a Y-intercept, which is a point where the extension line of the side of the boxes A and B in the Z-axis direction and the Y-axis intersect, is a1, a2, a
3, a4, b1, b2, b3, b4.

In the following, the appearance of the two boxes A and B to a person will be examined as follows.

First, the Y coordinate of the user, that is, the back side of the box B is represented by BR. Then, the Y coordinate of the other party, that is, the Y side of the back side of the box A is represented by AR. The Y coordinate on the left side of the back of the box B is represented by BL. Then, the Y coordinate of the left side of the box A is
Expressed by AL.

Further, the Y coordinate of the vertex pb1 (of the box B) is represented by B
1Y, the Y coordinate of vertex pb7 is represented by B7Y, the Y coordinate of vertex pa1 (of box A) is represented by A1Y, and vertex pa7
Is represented by A7Y.

Then, the height of the bottom surface of the self (box B) is BB
H, and the upper surface height of the other party (box A) is represented by AUH.

Further, WPB1X and WPA5X are obtained as follows.

WPB1X = WBX0 + WBY0 * COS (θ) WPA5X = WAX0 + WAY0 * COS (θ) + WAL +
WAW * COS (θ) where (WBX0, WBY0) = (pb1x, pb1y) (WAX0, WAY0) = (pa1x, pa1y). Also, the length of the opponent's box (A) is represented by WAL,
The width of the opponent's box (A) is represented by WAW.

In the present embodiment, the above notation is adopted, and if all of the following expressions are satisfied, no occlusion occurs. That is, it is determined that the box B is not hidden by the box A.

BR ≦ AL BL ≧ AR b4 ≧ a1 b2 ≦ a4 B7Y> A1Y B1Y <A7Y BBH ≧ AUH WPB1X ≧ WPA5X When such an inspection is completed in the correlation of all the boxes on the pallet, the judgment of hiding is made. finish. Generally, about 200 boxes are stacked on the pallet. Therefore, if the correlation of the permutation combination of the boxes is exhausted, the calculation time of the CPU becomes enormous, and the man-machine interface is deteriorated. Therefore, in the present embodiment, the following measures are taken.

In this embodiment, the drawing order of the boxes is always grasped. The drawing order is managed by a drawing order list structure. This drawing order list corresponds to the above-mentioned FIG.
As shown in the figure, “drawing order forward link” in JYOUDAN @ (−) and “drawing order back”
Link ". FIG. 7 shows a state where a list structure indicating the drawing order is formed by the two link pointers. As shown in FIG. 7, the “drawing order list head pointer” and the “drawing order list element number” are recorded in BYOUGA (−), and the “drawing order list head pointer” is the most significant. It points to the address where the data of the box to be drawn first is recorded. This address is the same as the above-mentioned JYOUD
This is an address within AN @ (-). In the example shown in FIG. 7, the first box to be drawn is box 1 and 2
The box to be displayed second is box 4. Hereinafter, boxes 2, 7, 8, and 9 are drawn in this order. In the last box 9, Φ is written as “drawing order forward link” to indicate that it is the last box.

When a new box is stacked on the pallet, the above-described drawing order list is updated as follows.

First, a check is made for each element to determine whether or not the newly loaded box is hidden in relation to each element (box) in the list. This check is performed by performing the above-described calculation, and is performed in order from the first element in the list. Then, when a box that hides a new box is first found in the drawing order list, a group of boxes after the box that hides the new box (hereinafter, referred to as group A) and the new box The drawing order list is divided into two groups, a group of boxes not to be hidden (hereinafter referred to as group B).

Then, a new box is added at the end of the group A.

Next, the same processing as the above-described newly added box is performed on each of the boxes included in the group B. That is, the boxes of the group B are inspected in turn to check whether or not the boxes of the group A are hidden. In this case, if a hidden box is found, the box included in Group B is placed at that position on Group A, and the box from the beginning to the placed box is named Group A. In addition, the part after the position of Group A is cut off and named as Group B. Then, for each of the boxes included in the group B, an inspection is performed on whether or not the boxes included in the group A are hidden in order. Such a process is repeated until the group B has no more boxes.

In this way, the drawing order list is divided one after another, and a new drawing order list is constructed. In order to realize such arithmetic processing, so-called recursive processing is employed in the present embodiment. By using a routine capable of recursive processing, it is possible to call itself from within the routine, and efficient computation is possible.

B. A method of designating a position at which boxes are stacked In order for an operator to specify a position at which boxes are to be stacked in a three-dimensional space, the operator must be able to see the space. However, the three-dimensional space becomes invisible to humans when there are obstacles that close their eyes,
It becomes impossible to specify the "position to be stacked". In the present embodiment, in order to solve this problem, the position of the human eye in the three-dimensional space is fixed (the viewing angle can be changed by a later instruction), and the appearance of the object in the three-dimensional space is changed. , The operator can easily indicate the position at which he or she wants to pile up.

A characteristic feature of the present embodiment is that it is possible to specify a position in a three-dimensional space by simultaneously displaying two types of figures to the operator. That is, the operator designates a place in a two-dimensional plan view while referring to a three-dimensional space image diagram, and the program interprets the intention of a person and displays a box at an "appropriate position" to display a "place to be stacked". "Has been determined.

At this time, in the interface between the computer and the operator, “resolution of computer screen”, “ambiguity of input device (mouse)” and “ambiguity of designation of person” are generated, Interpreting the location as it is would lead to excessive errors. Therefore, in order to achieve the position accuracy required for the robot to pile things, a predetermined interpolation is performed for the designated position by taking into account the "premise" and "interpretation" described later. Position accuracy.

B-1 Input Means In the present embodiment, all inputs and instructions are performed by using a mouse.

B-2 Display Means In the present embodiment, as described above, eight boxes flowing on the conveyor are always displayed in an elevation view in the order of flow,
This makes it easy for the operator to imagine the appearance. Further, the total volume ratio of all the boxes is displayed with 80% of the pallet length * width * permissible stacking height as 100 as a standard of the volume ratio on the pallet. This allows for efficient stacking.

The number of special containers (such as plastic boxes whose tops are open) is displayed as a whole to inform the operator of the possibility of special consideration. Further, in the so-called "pre-loading collapse rule", the volume percentage for the entire destination and the number of special containers are indicated for each destination unit (configured as described above). Further, a whole package elevation view screen 42 on the pallet and a whole package top view screen 44
Are simultaneously displayed in different windows so that the appearance of the cargo can be easily imaged by the operator.

B-3 Mapping In the present embodiment, the three-dimensional space and the two-dimensional display space are converted using the following conversion formula.

X = X + Ycos (θ) where:
θ is an arbitrary viewing angle.

Y = Z + Y sin (θ) where:
θ is an arbitrary viewing angle.

The two-dimensional coordinates (0, 0)-(320
0, 3200) is displayed in the two-dimensional CRT space of (0, 0)-(199, 199).

B-4 Assumption for Correcting Ambiguity As described above, the position specified by the operator in three dimensions has some ambiguity. In order to eliminate this ambiguity, the present embodiment presupposes that certain rules are predetermined.

Assumption 1: A person has a desire to stack boxes on a pallet in accordance with the "pre-loading and breaking rule".

Assumption 2: A person wants to stack as good as possible.

Assumption 3: It is assumed that the boxes to be stacked generally flow in the order of the delivery route regardless of the intention of the person.

B-5 Where the Operator Wants to Stack
How this interpretation of interpretation is performed by executing a plurality of steps below.

(Step 1) The determination of which box this box is about to be put on is made by searching for a box (including a pallet) on which the center of gravity of the player (actually) is located near the designated box. Done. This search is performed by searching for a desired box from the above-mentioned uppermost link list.

(Step 2) The following judgment is made as to whether or not the boxes this time are about to be stacked so as to form a bridge.

(Step 2-1) Near the left of the user (± 15
0 mm), look for a box with a top surface higher than its own bottom surface.

(Step 2-2) Near the depth of the user (±
At 150 mm), look for a box with a top surface higher than its own bottom surface.

(Step 2-3) Neighboring right of oneself (± 15
0 mm), look for a box with a top surface higher than its own bottom surface.

(Step 2-4) Near yourself (± 1)
At 50 mm), look for a box with a top surface higher than its own bottom surface.

(Step 2-5) The group of boxes found in the steps from step 2-1 to step 2-4 is referred to as group A. Then, the group A that satisfies the following conditions is searched.

XBL + α ≦ XAR ≦ XBG, YBU-α
≧ YAD ≧ YBD or XBL + α ≦ XAR ≦ XBG, YBU ≧ YAU ≧ YBD
+ Α or XBL + α ≦ XAR ≦ XBG, YAU ≧ YBU, YAD
≦ YBD Here, XAR is the right side of the box to be inspected in the group A, YAD is the side in front of the box, and XAU is the back side of the box. XBL is the left side of the box, YBU is the back side of the box, YBD is the side in front of the box, and XBG is the center of gravity of the box.

The above α is usually 10 mm to 20 mm.
It is a value of the degree, and is a number indicating how much the degree of the catch is seen. Specifically, it is a value determined depending on whether the box to be stacked is a cardboard box or a metal box.

A group of boxes satisfying any of the above conditions is referred to as a group L. The number of elements of the group L is represented by NL. This group L is a group of boxes that can be caught on the left side of their own box.

(Step 2-6) Next, the group A that satisfies the following conditions is searched.

XBR-α ≧ XAL ≧ XBG, YBU-α
≧ YAD ≧ YBD or XBR-α ≧ XAL ≧ XBG, YBU ≧ YAU ≧ YBD
+ Α or XBR-α ≧ XAL ≧ XBG, YAU ≧ YBU, YAD
≦ YBD Here, XAL is the right side of the box to be inspected in the group A, YAD is the front side of the box, and XAU is the back side of the box. Also, XBR is the right side of the box, YBU is the back side of the box, YBD is the side in front of the box, and XBG is the center of gravity of the box.

The above α is usually 10 mm to 20 mm
It is a value of the degree, and is a number indicating how much the degree of the catch is seen. Specifically, it is a value determined depending on whether the box to be stacked is a cardboard box or a metal box.

A group of boxes satisfying any of the above conditions is referred to as a group R. The number of elements of the group R is represented by NR. This group R is a group of boxes that can be caught on the right side of their own box.

(Step 2-7) Next, the group A is searched for one satisfying the following conditions.

YBU-α ≧ YAD ≧ YBG, XBL ≦ X
AL ≦ XBR-α or YBU-α ≧ YAD ≧ YBG, XBR ≧ XAR ≧ XBL
+ Α or XBU-α ≧ XAL ≧ XBG, XAR ≧ XBR, XAL
≦ XBL Here, XAL is the right side of the box to be inspected in the group A, XAR is the right side of the box, and YAD is the side in front of the box. XBR is the right side of the box, XBL is the left side of the box, YBU is the back side of the box, and XBG is the center of gravity of the box.

The above α is determined in step 2-5,
Same as 2-6.

A group of boxes satisfying any of the above conditions is referred to as a group U. The number of elements of the group U is represented by NU. The group U is a group of boxes that may be caught on the back side of the box.

(Step 2-8) Next, the group A that satisfies the following conditions is searched.

YBD + α ≧ YAU ≧ YBG, XBL ≦ XAL ≦ XBR
-Α or YBD + α ≧ YAU ≧ YBG, XBR ≧ XAR ≧ XBL
+ Α or XBD + α ≧ YAU ≧ YBG, XAR ≧ XBR, XAL
≦ XBL Here, XAL is the right side of the box to be inspected in the group A, XAR is the right side of the box, and YAU is the back side of the box. Also, XBR is the right side of the own box,
XBL is the left side of the box, YBD is the side in front of the box, and XBG is the center of gravity of the box.

Note that for the above α, step 2-5,
Same as 2-6 and 2-7.

A group of boxes satisfying any of the above conditions is referred to as a group D. The number of elements of the group D is represented by ND. This group D is a group of boxes that can be caught on the near side of the own box.

(Step 2-9) From the groups L, R, U, and D created in this way, the tallest box on the top surface is found, and the group L in the range from its height to its height-β is found. ,
Find the elements of R, U, D, and find the groups LL, RR,
UU and DD are created, and the number of each element is set to M
Expressed as L, MR, MU, MD. This number of elements ML,
The following step 2-1 is performed according to the values of MR, MU, and MD.
Any one or two or more steps of 0 to 2-13 will be executed.

(Step 2-10) The above ML, MR, M
At least 4 if both U and MD are not "0"
The dots support your box. That is, it becomes a complete bridge. Therefore, the highest top surface is determined as the height of the bottom surface of the user. Then, it recalculates the remaining free area of the box below it due to its own box, and removes it from the top link list when the remaining area is less than the specified value. On the other hand, the user's own box is inserted at a predetermined position in the uppermost linked list.

(Step 2-11) If neither ML nor MR is "0", the center of gravity YBG of the box is
If YAU ≧ YBG ≧ YAD for both L and RR groups, the bridge is a stable bridge, so this highest top surface is determined as the bottom height of one's own box. Then, it recalculates the remaining free area of the box below it due to its own box, and removes it from the top link list when the remaining area is less than the specified value. On the other hand, the user's own box is inserted at a predetermined position in the uppermost linked list.

(Step 2-12) If neither MU nor MD is "0", the center of gravity XBG of the box is
For both groups U and DD, if XAL ≧ XBG ≧ XAR, the bridge is a stable bridge, so this highest top surface is determined as the bottom height of the own box. Then, it recalculates the remaining free area of the box below it due to its own box, and removes it from the top link list when the remaining area is less than the specified value. On the other hand, the user's own box is inserted at a predetermined position in the uppermost linked list.

(Step 2-13) Similarly, the above M
If any three of L, MR, MU, and MD are not “0”, if a bridge is established by determining the position of the center of gravity, the loading position is adopted.

(Step 3) If the group A does not exist, positioning is performed by sliding the river to the rightmost end of the past river.
The case where the group A does not exist is a case where a click is made in a so-called wide area where nothing is placed. Even at this time, if there is a box underneath due to riding, the remaining area of the free area on the upper surface of the box underneath is calculated. If the remaining area falls below the specified value, the box is removed from the link list at the top. On the other hand, the user is inserted at a predetermined position in the uppermost link list.

(Step 4) Although the group A exists,
If the stable bridge condition is not satisfied, a process and a catch check are performed by abrasion. Rolling to the back and sliding to the left (in the present embodiment, the cargo is to be loaded from the left side) are performed. However, both the back and left sides do not rub across the boundaries of what they are riding. After processing by such a rubbing, a check is made to check for a frontal catch and a rightward catch. If the catch is found, it is determined that a click (designation) error has occurred, and the operator is prompted to input again. If there is no catch, the corrected position is adopted as the designated position, and the user's box is stacked at that position. If there is a box underneath because of your riding, calculate the remaining area of the free area on the top of the box, and if the calculated area falls below the specified value In
This box is removed from the top link list, while your box is inserted into the top link list at a predetermined position.

C. Adaptation of Robot to Work Environment In the present embodiment, as described above, the operator specifies the position at which the load is to be loaded, and calculates the optimum position based on the position. The robot loads the cargo at the optimum position calculated in this way. In the present embodiment, various devices are devised for the operation of the robot. Hereinafter, description will be made in order.

C-1 The left-handed and right-handed environment setting robots are allowed to work with a so-called right-handed or left-handed. Here, a so-called left-handed person is defined as a form in which objects are carried from the right side when viewed from the robot, and objects are carried from the left side to the right side. Conversely, right-handed is a form in which objects are carried from the left and piled up from the back right to the front left.

C-2 Parameters In the present embodiment, the user can specify five positions on the conveyor, that is, the position where the robot grasps the object. In this embodiment, this designation is stored and held as a parameter inside the apparatus. This parameter is (X, Y, Z, Θ). Each represents an X coordinate, a Y coordinate, and a Z coordinate, and the last Θ is a hand angle when the robot grasps an object.

C-3 Temporary Storage Location In the present embodiment, the user can designate five temporary storage locations, that is, locations where objects are temporarily stored. In this embodiment, this designation is stored and held as a parameter inside the apparatus. This parameter is (X, Y, Z, Θ). Each represents an X coordinate, a Y coordinate, and a Z coordinate, and the last Θ is a hand angle when the robot grasps an object.

C-4 Operation Mode The device according to the present embodiment includes a real-time mode,
It has two operation modes, a simulation & execution mode. In each mode, two types of execution methods, step execution and automatic execution, can be adopted.

[0119] The real-time mode is a mode in which the robot loads a cargo such as a cardboard box on a pallet according to an instruction of the operator. The simulation & execution mode is a mode in which the loading of a load is simply performed on a computer without moving the object. In this mode, the result of the simulation is stored and held inside the computer, and in the execution stage, the apparatus automatically reconstructs the actual one based on the internally stored operation without any manipulation by an operator. It instructs the robot to load.

C-5 Parameters Designated by User In the present embodiment, the position and size of the pallet,
In addition, the user can set the allowable stacking height. That is, the position, size, and allowable stacking height of the pallet can be specified by the user as parameters.

D. Matters Concerning Human Operations According to the present embodiment, it is possible to calculate an optimum loading position and promptly perform loading by a robot according to an instruction from the operator.

Further, according to the present embodiment, all the operations including the operation guidance can be performed by a mouse click, and no keyboard input is performed.

Further, all operations such as redoing of stacking and redoing of selection of operation guidance can be performed. In particular, in the present embodiment, redoing for packing is performed on a conveyor, a temporary storage,
The background of the movement between the pallets and the hand rotation at that time must also be restored. Therefore, an operation procedure list having the data structure shown in FIG. 8 is created together with the operation, and the problem is solved.

The OPESEQ {(-) shown in FIG.
Is a data structure using openo as an index, and includes items such as a movement start id and a movement destination id.

The movement starting point id represents the starting point when the operation is the movement of an object. FIG. 9 shows an example of the movement starting point id. As shown in FIG.
The movement starting point id is a conveyor A, B, C, D, E, or a temporary storage location 1, 2, 3, 4, 5, or the like.

The destination id indicates the destination when the operation is a movement of an object. This destination i
An example of d is also shown in FIG. As shown in FIG. 9, the destination id is the pallet P, the temporary storage locations 1, 2,
3, 4, 5, etc.

The current slip number and the record number in the current slip represent the number of the slip handled at the time of the operation and the record number of the slip.

The box number in the record indicates the number of the box in the record.

The element number of the corresponding box basic management table indicates the element number in the basic management table holding all the data of the box. Data linking is performed by this element number.

The rotation identification indicates whether or not the boxes are stacked with the orientation changed, and an example thereof is also shown in FIG. As shown in FIG. 9, this rotation identification takes a value of 1 or 2, and if it is 1, it means that it does not rotate, and if it is 2, it means that it rotates 90 °.

The type code indicates the type of the contents of the box to be loaded.

L, W, and H represent the length, depth, and height of the box, respectively.

The source of movement represents the starting point when the box is moved, and its position is represented by X, Y, and Z coordinates. An explanatory diagram of the X coordinate, Y coordinate, and Z coordinate is shown in FIG. As shown in FIG. 10, these coordinates are a coordinate system based on the origin of the upper surface of the pallet. The values of X, Y, and Z in OPESEQ @ (-) are relative coordinates from the pallet origin at the left corner of the box.

In other words, changing the river on the screen generally makes it difficult to specify the point by specifying the location of the mouse click. For this reason, in the present embodiment, a menu for a special “river change” operation guidance for river change is provided to facilitate designation of river change. In FIG. 2 described above, there is a menu "River change" at the lower right of the operation guidance screen 46. This menu is a menu for opening the operation guidance screen for smoothly performing the river change. In the present embodiment, this operation is also registered in OPESEQ @ (-) as an operation procedure list similarly to the above-described movement. FIG. 11 shows how this operation is registered in the operation procedure list.

In this embodiment, only a rectangular parallelepiped box is considered as a box to be put on the pallet, but there are many special boxes. For example, there are boxes on the box that can only be the same, or ones that are longer or wider than that. Such a special container is displayed on the screen in a color different from that of other normal boxes, so that the operator can recognize that the box has a special characteristic.

E. Other important data structures and files
Structure In the random palletizing apparatus according to the present embodiment, various files for management are provided in the personal computer 12.

E-1 Product Type Master File HINSHU. TXT and HINSORT. Two master files with TXT are provided. this house,
HINSHU. TXT is a file in which HINNSHU is recorded at random, and HINSORT. TXT is
The master file of the type is sorted by the type code, and both have the same format. An explanatory diagram of the format of these files is shown in FIG. In addition, those with * in the first column indicate comment lines, and specific examples thereof are shown in FIG. 13 described later. Further, in the present embodiment, data in a format as shown in FIG.
It is stored in STAR (-). FIG. 12 shows this accumulated state. This MASTAR ＄
(-) Is stored in the personal computer 12. Also, the max of the read record is suppressed by IMAX.

E-2 Slip file DENPYOU. A file named TXT is stored in the personal computer 12
Is stored within. An explanatory diagram of the format of this file is shown in FIG. In FIG. 13, those with * in the first column indicate comment lines. However, unlike the type master file, the comment line in this slip file has a meaning. That is, in the present embodiment, the comment lines indicate the start / end of the slip and the start / end of the pallet. These breaks, as shown in FIG.
Each pallet and each slip have a nest structure. FIG.
In the example shown in FIG. 13, the format of the order record that controls the break by interpreting the nested structure by this comment is as shown in FIG.

E-3 Internal Slip Management Array Variable The internal slip management array variable DENPYO $ (-,-)
It is stored inside the personal computer 12. This array variable is
By referring to the slip file and the product master file, it is an array variable for managing the contents of the slip in a two-dimensional array with one pallet and one slip. An explanatory diagram of this array variable is shown in FIG. Since this array variable is a two-dimensional array, it can be represented in the form of a table as shown in FIG. Here, "END" is inserted at the end of the array indicated by the slip number IDX to indicate the end of the record.

E-4 Slip Decomposition Data Slip decomposition data DSPREC # (-) is a one-dimensional array in which one voucher is decomposed not for each order record but for each box, and the information is sequentially stored. The format of the slip disassembly data is shown in FIG. FIG. 15 shows a state in which data of a plurality of slips is represented in a table format.

E-5 Temporary Placement Management KARIOKI1
(-) To KARIOKI5 (-) are variables for managing boxes in the temporary storage area. In the present embodiment, five temporary storage locations are prepared, and five variables are provided for each temporary storage location. still,
Each variable KARIOKI1 {(-) to KARIOKI5}
The format of (-) is the same, and a detailed explanatory diagram is shown in FIG.
Is shown in The number of boxes placed in each temporary storage area is KNO1, KNO2, KNO3, KNO4, KNO
It is represented by 5.

F. Important Variables In the random palletizing apparatus according to the present embodiment, the following variables are used in software provided in the personal computer 12.

F-1 Operation Guidance Selection Number The variable that holds the operation guidance selection number is SL.
There are CT1, SLCT2, SLCT3, SLCT4, and BKNO. These variables are variables that indicate an operator's instruction on the operation guidance screen 46.

SLCT1 is a variable representing an operator's instruction on the first level 50 on the operation guidance screen 46. When this SLCT1 is 1, it means “from the conveyor to the pallet”, when it is 2, it means “from the conveyor to the temporary pallet”, when it is 3, it means “from the temporary pallet to the pallet”, Sometimes it means "Kawari". In the case of 5, it means "redo". In addition, SL
If CT1 is 5 and it means redo, the degree of influence of redo is specified by the variable BKNO. This variable BKNO will be described later.

[0145] SLCT2 is a variable representing an operator's instruction on the second level 52a on the operation guidance screen 46. When this SLCT2 is 1, it means "no rotation", when it is 2, it means "90 degree rotation", and when it is 3, it means "redo".

SLCT3 is a variable representing an operator's instruction on the second level 52b on the operation guidance screen 46. When this SLCT3 is 1, it means that "Temporary Placement 1 has been designated", and when this SLCT3 is 2, it has "Specify Temporary Placement 2".
3 means "designate temporary 3",
A value of 4 means that "temporary placement 4 has been designated", and a value of 5 means that "temporary placement 5 has been designated". Also,
A value of 6 means "redo".

[0147] SLCT4 is a variable representing an operator's instruction on the third hierarchical level 54a on the operation guidance screen 46. As described above, the third layer 54a is a layer that displays a message "Where on the pallet?", And the operator specifies the position to be stacked with the mouse according to the instruction. When the variable SLCT4 is 1, it means that "place designation" has been performed, and when it is 2, it means "redo", that is, a click with the right mouse button has been made.

The variable BKNO is a variable referred to when the variable SLCT2 is 6 (that is, “redo”), and is a variable indicating the extent to which the rework affects. When this variable BKNO is 1, it means redoing across slips, when it is 2, it means redoing over order records, and when it is 3, it means simply backing up, 4 indicates that restoration to temporary storage is performed, and 5 indicates that river replacement is restored.

F-2 Environmental Variables Various other environmental variables are prepared for managing conveyors and temporary storage. Hereinafter, examples of typical variables will be described.

The variable ORIGIN is a variable for designating left-handed or right-handed. A value of 1 indicates left-handed and a value of 2 indicates right-handed.

Variables CVAX0, CVAY0, CVAZ
0, CVAHAND represents the robot coordinates of the conveyor A. Variables CVBX0, CVBY0, CVBZ0, CVB
HAND represents the robot coordinates of the conveyor B. Variable C
VCX0, CVCY0, CVCZ0, CVCHAND
Represents the robot coordinates of the conveyor C. Variable CVDX
0, CVDY0, CVDZ0, and CVDHAND represent the robot coordinates of the conveyor D. Variables CVEX0, CVE
Y0, CVEZ0, and CVEHAND represent the robot coordinates of the conveyor E.

Variables KA1X0, KA1Y0, KA1Z
0, KA1HAND represents the robot coordinates of temporary placement 1. Variables KA2X0, KA2Y0, KA2Z0, KA2
HAND represents the robot coordinates of the temporary storage 2. Variable KA
3X0, KA3Y0, KA3Z0, KA3HAND
The robot coordinates of the temporary storage 3 are shown. Variable KA4X0, KA
4Y0, KA4Z0, and KA4HAND represent the robot coordinates of the temporary storage 4. Variables KA5X0, KA5Y0, KA
5Z0 and KA5HAND represent the robot coordinates of the temporary placement 5.

In the present embodiment, the SIMF
A variable called LG is prepared. This variable SIMFL
G is a variable that specifies whether a simulation is performed or a load is actually loaded. In the present embodiment, when the variable is 1, it means a simulation, and when it is 2, it means that a load is actually loaded. Further, in the present embodiment, it is possible to select the execution mode between step execution and automatic execution which is continuously executed. When the value of the variable EXMODE is 1, the step execution is performed, and when the value is 2, the automatic execution is continuously performed. The step execution and the automatic execution will be described later in detail.

In addition, PAREL, PAREW, HLIM
IT is a variable representing the length, width, and allowable height of pallets, respectively.

F-3 Correction variables are prepared to absorb certain errors and the like when loading correction variables.

The variable LYOYU indicates the time limit interval from the leftward sliding, and is set to, for example, 10 mm in the present embodiment. The variable RYOYU indicates a time limit interval from the rightward sliding. The variable UYOYU indicates the time limit interval from the upward sliding. The variable DYOYU indicates the time limit interval from the downward sliding.

The personal computer 12 according to the present embodiment
In the software inside, THETA, α,
BETA and GANMA are used. Where THE
TA is a constant of the viewing angle, and its value is π / 6. α
Is a number indicating the degree of the above-mentioned catch, and is 10 mm in the present embodiment. BETA is an interference candidate neighborhood value, and in this embodiment, the value is 150
mm. GANMA is an adopted neighborhood value, and in this embodiment, the value is 100 mm.

G. First Embodiment FIG . Real-time mode and simulation
As described above, the random palletizing apparatus according to the present embodiment allows the operator to easily indicate the position to be stacked with the mouse by displaying the real stacking diagram to the operator.

Further, the random palletizing apparatus according to the present embodiment has a real-time mode and a simulation mode as operation modes. Hereinafter, these two operation modes will be described.

The real-time mode is a mode in which the operator designates a moving place and at the same time designates its coordinates to the robot to give an operation instruction. As a matter of course, since the operation instruction is issued to the robot at the same time when the position is specified, the degree of freedom of the retry is not large. Although it is theoretically possible to convey the redo as it is as the reverse action immediately before, in the world of logistics, the next cargo to be loaded often arrives, so in general, virtually Have difficulty.

The simulation mode is a mode in which even if the operator specifies the position, the details are recorded only on the computer and the robot is not simultaneously instructed to operate. In the random palletizing apparatus according to the present embodiment, the break of the simulation is performed by confirming the package state determination for each pallet. The determined package is recorded in a file and executed by specifying the file name with the robot control utility. In this case, there is a feature that the user can redo as many times as necessary until the package is determined. The file name in which the determined package is recorded can be freely specified by the operator.

That is, in the real-time mode, the operator designates the position where the boxes are to be loaded, and at the same time, the operation instruction is issued to the robot. The robot is not instructed just by recording this instruction. Then, in the simulation mode, when the operator issues an instruction to fix the package on one pallet, the stacking order of the one pallet is recorded in a predetermined file. In other words, the stacking on the pallet can be repeated any number of times before an instruction to fix the packing style on one pallet is issued. The stacking order thus recorded in the file is then executed by the robot control utility. The program called the robot control utility instructs the robot to perform loading according to the loading order recorded in the file.

In general, the order of goods to be conveyed in physical distribution is often determined. For example, a large number of merchandise is often flown in one store in order. When the order in which the products flow is determined in advance as described above, it is preferable to determine the stacking order in advance in the simulation mode. As described above, in the simulation mode, it is possible to redo as many times as necessary until the instruction to confirm the packing state is issued on one pallet. Therefore, it is necessary to determine in advance a suitable packing procedure with a high filling rate. Is possible. Then, the determined order is recorded in a file, and the robot control utility can automatically perform the stacking according to the order. At this time,
Needless to say, the operator does not need to perform any operation, and only needs to monitor the state of the stacking on the screen.

H. Step Execution and Automatic Execution In the random palletizing apparatus according to the present embodiment, it has been described that the operation modes include a real-time mode and a simulation mode. And
In the simulation mode, the robot control utility issues an operation instruction to the robot according to the order of the operations recorded in the file, and states that the operator need not give a specific operation instruction.

The robot control utility has two execution modes.
One is a step execution mode, and the other is an automatic execution mode.

The step execution mode is a mode in which an operation is instructed to the robot by the operator pressing the ENTER key for each operation. On the other hand, the automatic execution mode is an execution mode in which a predetermined file is automatically read out after the utility is started, and stacking is continuously performed.

In general, it is preferable to carry out continuous loading in the automatic execution mode. However, in experiments, tests, verifications, and the like, the operator executes each operation in the step execution mode. It may be necessary to proceed while confirming. In such a case, the step execution mode is a useful mode.

I. Interface with Robot Hereinafter, an outline of an interface with the robot 22 and the robot 28 in the random palletizing apparatus according to the present embodiment will be described.

I-1 Communication Sequence Communication with the robots 22 and 28 is performed by an XWRITE command or a VAL command.

In the XWRITE command, predetermined coordinates are designated by the parameter “from” and the position data indicated by “to”. In response to this command, a signal such as ACK or NAK is returned from the robots 22 and 28 to confirm that the command has been received.

The VAL command is used for checking the completion of the operation. That is, by performing polling using this VAL command, it is confirmed whether or not the operations of the robots 22 and 28 have been completed. At this time, the robots 22 and 28 return interlock data.

I-2 Communication Message Format The communication message format of the command XWRITE described above is shown in FIG.
Is shown in As shown in FIG.
(Start of text) is hex "02",
The device NO (number) is, for example, “00”.

The "command" shown in FIG.
In the case of the XWRITE command, "(" is used, the write start variable name is "H", the write end variable name is "T", and the interlock value is "+00001" at the start of the palette. Is set to XWRITE
It is incremented (+1) each time a message is sent.

Further, as shown in FIG.
The OM includes four parameters of X, Y, Z, and Θ, and among them, X, Y, and Z are “+ NNNNNN” or “−NNNNNN” and indicate the robot coordinates. This unit is 0.1 mm. Θ is “+ MMMM
M "or" -MMMM ", indicating the robot hand angle, where the unit is 0.1 degree.
The same applies to X, Y, Z, and に つ い て.

The dimensions include three parameters of L, W, and H. These parameters are expressed as “+ LLLL”.
L "or" -LLLL ", which represents the size of the box.
This unit is 0.1 mm. The type code which is a box characteristic is “+ XXXXXX”, which indicates the type code.
For example, “+00001” means a plastic box. The BCC is a code obtained by performing a logical addition of eight unit bits from after the STX to before the BCC, and converting the result into two hexadecimal characters. Finally, the data break is
Hexa 0D.

FIG. 19 shows a communication message format of the command VAL. In FIG. 19, STX (start of text) is hex similarly to the XWRITE command.
“02” and the device number (number) is XWRIT
For example, it is "00" like the E command.

The "command" shown in FIG.
In the case of the AL command, it is Hexa “27”, the read start variable name is “C”, and the read end variable name is “C”. In addition, the BCC uses the XWRITE
8 from STX to BCC before command
Logical addition of unit bits is performed, and the result is expressed as 16 characters of two characters.
This is the code converted to hexadecimal characters. Finally, the data delimiter is Hexa 0D, similarly to the XWRITE command.

FIG. 20 shows a communication message format of ACK / NAK. In FIG. 20, STX (start of text) is hex similarly to the XWRITE command.
"02". In the ACK / NAK part, A
“=” Is set for CK, and “−” for NAK.
Is set. In addition, the BCC uses the XWRITE
8 from STX to BCC before command
Logical addition of unit bits is performed, and the result is expressed as 16 characters of two characters.
This is the code converted to hexadecimal characters. Finally, the data delimiter is Hexa 0D, similarly to the XWRITE command.

I-3 Interlock The interlock of the data transmitted to the robot via the personal computer 12 is handled by the variable name H. When the pallet starts, the interlock value is set to “+00001”
Every time the position data is transmitted, an increment (+1) is made. The interlock at the completion of the operation of the robot is performed via the variable name C. This is performed by setting the variable name C to “+00001” at the start of loading on the pallet.

That is, first, when the computer writes the transmission interlock to the variable name H, the robot recognizes that new data has been sent because the variable H has changed from the previous one. Thereafter, when the robot completes the operation, the robot writes a completion interlock to the variable name C. By detecting that the completion interlock is different from the previous one, the computer can determine that the operation according to the operation instruction immediately before (by the computer) has been completed (at the robot). It is.

I-4 Number of Failure Retries The number of retries (retries) when a NAK is returned from the robot or a BCC error is detected is set to 5 in this embodiment.
That is, if NAKs are returned five times in a row, it is considered that a failure has occurred and a warning is issued to the outside. In this embodiment, in the case of no response (no change in operation completion), infinite polling is repeated.
Even in this case, the control can be stopped by the operator pressing the STOP key on the computer side.

J. Specific Example of Operation Hereinafter, a specific example of the operation in the simulation mode of the present embodiment will be described in detail with reference to the drawings.
The only difference between the simulation mode and the real-time mode is whether the stacking operation order is saved as a file, and the other points are exactly the same.

Simulation Mode The state in which six boxes are stacked from the state of FIG.
It is shown in FIG. FIG. 2 shows a state in which boxes are not yet stacked on the pallet. In the mode shown in FIG. 21, a state in which one box is temporarily stored in the temporary storage space 3 is shown.

In FIG. 22, the operation guidance screen 46 is displayed.
The appearance of the third hierarchy 54a is shown. FIG.
When the third hierarchy 54a appears, the operator must move the mouse cursor to specify the position where the boxes are to be stacked, as described with reference to FIG. For example, in the example shown in FIG. 22, the operator designates the position where the boxes are to be stacked on the overall package top view screen 44.

The numerical values shown in the lower part of the whole package elevation view screen 42 are robot coordinates X, Y, Z, and Θ.

FIG. 23 shows a state where the boxes are stacked at the designated positions in FIG. By comparing FIG. 22 with FIG. 23, it will be understood that the boxes are stacked at the position specified by the operator.

FIG. 24 shows an example in which when a box is further stacked from the state shown in FIG. 23, an instruction is given by the mouse cursor so that the boxes are stacked on the box. ing.

FIG. 25 shows a state in which boxes are stacked at the designated position in FIG. By comparing FIG. 24 with FIG. 25, it will be understood that the boxes are stacked at the position specified by the operator.

FIG. 26 shows a state where several boxes are placed in the temporary storage place. In the example shown in FIG. 26, one box is placed in the temporary storage 1 and two boxes are placed in the temporary storage 2.

FIG. 27 shows a state where two boxes are newly stacked from FIG. Here, it should be noted that these two new boxes are not conveyed from the temporary storage locations 1 and 2 but are conveyed from a conveyor. If the input display screen 40 of FIG. 26 and FIG. 27 is compared, FIG.
It will be understood that the boxes displayed at positions 1 and 2 on the input display screen 40 at 6 have been newly stacked.

FIG. 28 shows a state in which the boxes placed in the temporary storage 1 are stacked from the state shown in FIG. As can be understood from FIG. 28, the boxes that were in the temporary storage 1 are stacked on the two newly stacked boxes in FIG.

FIG. 29 shows a state where two boxes transported from the conveyor and two boxes placed in the temporary storage 2 are stacked from the state shown in FIG. ing.

FIG. 30 shows a state where the "river" in the second column has just been completed. It can be seen that just two rivers have been formed, as shown in the overall load plan view screen 44 of FIG. That is, FIG.
0 is a diagram showing that the river change is established.

FIG. 31 shows a diagram in which the upper box is placed protruding from the upper surface of the lower box. Even in such a case, if the center of gravity of the upper box is within the upper surface of the lower box, it can be placed.

In FIG. 32, in the middle of the river in the third row, four small boxes are stacked in a so-called rice-shaped shape in the first row, and three similar small boxes are stacked in the second row. Is shown. In FIG. 32, the mouse cursor indicates the position of the fourth box in the second row, and the fourth box is about to be stacked in the second row.

FIG. 33 shows a state where small boxes are stacked at the position designated in FIG. As a result, it can be understood that small boxes are stacked in a so-called cross-shaped shape in both the first and second stages.

FIG. 34 shows a state in which one large box is stacked on eight small boxes stacked in a two-stage cross-shaped shape shown in FIG. This is the so-called bridge condition, in which the large box is supported by the four smaller boxes below.

FIG. 35 shows a state in which the stacking has further progressed from FIG. In the example shown in FIG. 35, one large box is placed in the temporary storage space 1.
This was set aside for later on the folding container. How to use the box placed in the temporary storage 1 will be described later.

FIG. 36 shows a state in which the river has been changed from the state of FIG. 35 and the stacking has progressed.

FIG. 37 shows a state in which the stacking has been further advanced from the state of FIG. Further, FIGS. 38 and 39 also show how the stacking sequentially proceeds from the state of FIG. 37.

In FIG. 40, the large box 60 set aside in the state shown in FIG.
It is shown that it is put on the. In the present embodiment, the folding container 58 has no lid,
As a result, a box having a bottom surface smaller than the top surface of the folding container 58 cannot be placed on the folding container 58. Therefore, as described above, the folding container 58
When a sufficiently large box 60 is conveyed, the large box 60 is stored in the temporary storage place 1 (may be 2 to 4), and after the folding container 58 is loaded, the large box 60 is folded. It is possible to stack on the con 58.

In FIG. 40, the stacking of one pallet has been completed. When the packing is completed in this way, a message "Do you want to confirm the packing?" Is displayed on the operation guidance screen 46 (FIG. 40).
reference).

[0203] On the other hand, if the "Y" key is pressed, the package is determined. On the other hand, if the "N" key is pressed here, the packing state is not determined, and it is possible to start packing again from the beginning. That is, the description of the present operation example describes the stacking in the simulation mode, but the instructions and operations for the stacking in the real-time mode are exactly the same. The difference is that the message "Do you want to confirm the package?" As shown in FIG. 40 is not displayed in the real-time mode.

Further, in this operation example, when the "Y" key is pressed, the package is determined, but it is necessary to specify a file name for storing and storing the packing order. Therefore, when the "Y" key is pressed as described above, the message "storage file name?" Is displayed at the bottom of the operation guidance screen 46, and the user is prompted to input a file name for recording the order of stacking. .

As described above, when the stacking for one pallet is completed and the file name or the like to be recorded is designated, all the stacking procedures are recorded in the file. When this recording is completed, the screen shows the state of the new pallet as shown in FIG. 41, and the preparation for new stacking has already been completed.

Robot control utility As shown in the above-described operation example, every time the loading on one pallet is completed, the loading procedure is recorded in the file with the designated name. The stacking procedure recorded in this way is executed using the robot control utility described above.

FIG. 42 shows a start screen of the robot control utility. As shown in FIG. 42, when activated, the robot control utility firstly displays a message prompting the user to specify a confirmed package file to be executed. The operator follows the message
Enter the name of the file to be executed. In FIG. 42, for example, as the file name, HONBAN. LOG is specified.

As shown in FIG. 42, the screen of the robot control utility is the whole elevation view screen 70.
, Temporary storage area screen 72, target box and location information screen 74
And a message screen 76.

[0209] The whole elevation view screen 70 is almost the same as the above-mentioned whole package elevation view screen 42, but the lines of the space, which is the limit of stacking boxes, are not displayed. That is, only one pallet is displayed on the entire elevation view screen 70 in the initial state.

[0210] On the temporary storage area screen 72, the state of the temporary storage area,
Specifically, what kind of box is placed in each of the temporary storage places 1 to 5 is shown.

[0211] The target box and location information screen 74 displays the contents of the box and various types of information such as where to go to which location.

[0212] As described above, the message screen 76
This is a screen on which the user specifies a confirmed package file and the operator gives various instructions.

FIG. 43 shows a state where a message for performing the step execution is displayed on message screen 76. As described above, the execution modes in the robot control utility include the step execution mode and the automatic execution mode. FIG. 43 shows an example in which this step execution mode is adopted. For this reason, the message screen 76 displays "Step execution.
Then press any key. Is displayed, and a key input from the operator is waited for every movement for transporting the box. The operator monitors the screen, and if the various values displayed on the mask and the package appearance are normal, the operator presses some key to proceed with the stacking.

FIG. 44 shows a state in which the key is pressed several times from the state shown in FIG. 43 and the stacking is advanced.
Further, FIG. 45 shows a state where the stacking has progressed and immediately before the last large box is placed on the folding container.

[0215]

According to the first aspect of the present invention, the operator can specify the loading position by the indicating means while watching the loading state, so that a random palletizing device that can be easily stacked can be provided. Play.

According to the second aspect of the present invention, since the operation guidance is displayed, there is an effect that a random palletizing apparatus in which an instruction operation is easy can be obtained.

According to the third aspect of the present invention, it is possible to provide a random palletizing apparatus which allows an operator to specify an accurate loading position while looking at a perspective view and a plan view.

According to the fourth aspect of the present invention, it is possible to provide a random palletizing device which allows the operator to easily instruct a temporary storage place to place a load.

According to the fifth aspect of the present invention, since a simulation mode is provided, it is possible to virtually perform a so-called dry-run exercise of loading without actually loading. In addition, since the simulated loading order is stored and actual loading can be performed in accordance with this order, there is an effect that a random palletizing device that can easily perform automatic loading can be provided.

[Brief description of the drawings]

FIG. 1 is a configuration diagram of a random palletizing apparatus according to a preferred embodiment of the present invention.

FIG. 2 is an explanatory diagram showing a state of a screen of a personal computer of a random palletizing apparatus according to a preferred embodiment of the present invention.

FIG. 3 is an explanatory diagram of a hierarchical structure of an operation guidance screen on a personal computer screen of a random palletizing apparatus according to a preferred embodiment of the present invention.

FIG. 4 is an explanatory diagram illustrating a data structure of one box in a random palletizing apparatus according to a preferred embodiment of the present invention.

FIG. 5 is an explanatory diagram showing that among boxes stacked on a pallet, only a box located at the top has a list structure.

FIG. 6 is an explanatory diagram of a hiding determination method according to the present embodiment.

FIG. 7 is an explanatory diagram showing how a list structure indicating the drawing order of boxes is formed in the present embodiment.

FIG. 8 is an explanatory diagram illustrating a data structure of an operation procedure list in the present embodiment.

FIG. 9 is an explanatory diagram showing an example of a movement starting point id in an operation procedure list in the present embodiment.

FIG. 10 is an explanatory diagram of an X coordinate, a Y coordinate, and a Z coordinate when a movement start point id and the like are designated in the present embodiment.

FIG. 11 is an explanatory diagram of a format of a product type master file used in the present embodiment.

FIG. 12 is an explanatory diagram showing how data is read from a master file of a product type and stored in MASTAR $ (-) in the present embodiment.

FIG. 13 is a diagram showing the structure of DENPYOU. T
It is explanatory drawing of the format of the file called XT.

FIG. 14 is an explanatory diagram of an internal slip management array variable DENPYO $ (-,-) stored in the personal computer.

FIG. 15 is an explanatory diagram in a case where data of a plurality of slips is represented in a table format in the present embodiment.

FIG. 16 is an explanatory diagram showing the format of individual slip disassembly data in the present embodiment.

FIG. 17 shows a variable KARIOKI1 {(−) to KARIOKI5} corresponding to the temporary storage space in the present embodiment.
It is explanatory drawing showing the form of (-).

FIG. 18 is an explanatory diagram showing a communication message format of a command XWRITE output from the random palletizing device to the robot in the present embodiment.

FIG. 19 is an explanatory diagram showing a communication message format of a command VAL output from the random palletizing device to the robot in the present embodiment.

FIG. 20 shows commands ACK / NAK output from the random palletizing device to the robot in the present embodiment.
FIG. 4 is an explanatory diagram showing a communication message format of FIG.

FIG. 21 is a diagram illustrating an example of a state in which six boxes are stacked from the state illustrated in FIG. 2 using the random palletizing apparatus according to the present embodiment.

FIG. 22 is an operation explanatory diagram showing a state where a third hierarchy appears on the operation guidance screen.

FIG. 23 is an explanatory diagram showing a state where boxes are stacked at positions designated in FIG. 22;

FIG. 24 is an explanatory diagram showing a state in which, when a box is further stacked from the state shown in FIG. 23, an instruction by a mouse cursor is performed so that the boxes are stacked on the box;

FIG. 25 is an explanatory diagram showing a state where boxes are stacked at positions designated in FIG. 24;

FIG. 26 is an explanatory diagram showing a state where several boxes are placed in a temporary storage place.

FIG. 27 is an explanatory diagram showing a state where two new boxes are stacked from the state of FIG. 26;

FIG. 28 is an explanatory diagram showing a state where the boxes placed in the temporary storage place are stacked from the state shown in FIG. 27;

29 is an explanatory diagram showing a state in which two boxes transported from the conveyor and two boxes placed in the temporary storage 2 are stacked from the state shown in FIG. 28.

FIG. 30 is an explanatory diagram showing a state where the “river” in the second column is completed.

FIG. 31 is an explanatory diagram of a state in which the upper box is placed so as to protrude from the upper surface of the lower box.

FIG. 32 shows a state in which four small boxes are stacked in a so-called rice-shaped shape in the middle of the river in the third row, and three similar small boxes are stacked in the second row. FIG.

FIG. 33 is an explanatory diagram showing a state where small boxes are stacked at a position designated in FIG. 32;

FIG. 34 is an explanatory diagram showing a state in which one large box is stacked on eight small boxes stacked in a two-tiered cross shape shown in FIG. 33;

FIG. 35 is an explanatory diagram showing a state in which stacking has further progressed from FIG. 34;

FIG. 36 is an explanatory diagram showing a state in which river change has been performed from the state of FIG. 35 and packing has proceeded.

FIG. 37 is an explanatory diagram showing a state in which stacking has further progressed from the state in FIG. 36;

FIG. 38 is an explanatory diagram showing a state in which stacking sequentially proceeds from the state of FIG. 37.

FIG. 39 is an explanatory diagram showing a state in which stacking proceeds sequentially from the state of FIG. 37.

40 is an explanatory view showing a state where the large box set aside in the state shown in FIG. 35 is placed on a folding container;

FIG. 41 is an explanatory diagram showing a state where loading of one pallet has been completed and a new pallet having no boxes loaded thereon is displayed on the screen.

FIG. 42 is an explanatory diagram showing a startup screen of the robot control utility according to the present embodiment.

FIG. 43 is an explanatory diagram showing a state where a message for performing step execution is displayed on the message screen.

FIG. 44 is an explanatory view showing a state where the key is pressed several times from the state shown in FIG. 43 and the stacking is advanced.

FIG. 45 is an explanatory diagram showing a state where the stacking has progressed from the state shown in FIG. 44 and immediately before the last large box is placed on the folding container.

[Explanation of symbols]

10 Top distribution computer, 12 PC, 14
Normal loading equipment, 16 PLC communication station, 18
Network loading device, 20 robot controller, 22 robot, 24 sequencer, 26 robot controller, 28 robot, 30 sequencer, 40
Input display screen, 42 overall packaging elevation view screen, 44 overall packaging plan view screen, 46 operation guidance screen, 50 first level, 52a, 52b, 52c second level, 54a,
54b, 54c Third layer, 56 fourth layer.

Claims (5)

[Claims] 1. In a random palletizing apparatus for loading a plurality of conveyed loads on a pallet using a manipulator based on an instruction of an operator, an appearance of the plurality of conveyed loads is shown to the operator. Input display means for displaying to the operator the size and shape of the plurality of loads, information display means for displaying the contents of the plurality of conveyed loads to show to the operator, An output display means for displaying, to the operator, a stacking view showing a state in which a load is being loaded on the pallet; and the operator on the stacking view displayed by the output display means. An instructing means for instructing a position at which a load is to be loaded next, based on the instruction of the above; And sending means for sending the optimum loading position calculated by the optimum loading position calculation means to the manipulator.The contents of the load include at least a type and an item name of the load, and load the load on the manipulator. A random palletizing device characterized by loading at the optimum loading position. 2. The random palletizing apparatus according to claim 1, further comprising: an operation guidance display unit that provides an operation guidance for guiding the operator how to instruct a stacking operation. Palletizing equipment. 3. The random palletizing apparatus according to claim 1, wherein the output display means includes: a perspective view display means for displaying a perspective view showing a state in which a load loaded on the pallet is viewed obliquely; And a plan view display means for displaying a plan view showing the state of the cargo as viewed from above. 4. The random palletizing apparatus according to claim 1, wherein said instruction means includes temporary placement instruction means for instructing to load a cargo at a temporary storage place instead of on said pallet. . 5. The random palletizing apparatus according to claim 1, further comprising: a real-time mode;
And control means for switching between a simulation execution mode and the real-time mode. In the real-time mode, the robot actually loads a load on a pallet in accordance with an instruction of the operator. In the simulation execution mode, loads a real load. Virtual loading on the computer without
A simulation stage for storing the loading procedure and an execution stage for loading the actual load based on the loading procedure stored in the simulation stage after the execution of the simulation stage are executed. A random palletizing device.